Apparatus and method for the controlled lubrication and cleaning of conveyors

ABSTRACT

A method for automatically cleaning and lubricating conveyor belt systems is disclosed. A microprocessor controlled control unit senses the movement of the conveyor belt and the presence of items, for example bottles, on the conveyor. The control unit initiates the application of lubricant, detergent and rinse water onto the conveyor according to the speed of the conveyor, the presence of items and the time passed since the previous application. If the conveyor is stationary, that is, is not in motion, no lubricant or cleaning solution is applied. If the conveyor is moving but no items are on the belt, a reduced amount of lubricant is dispensed onto the conveyor system. The conveyor cleaning and lubricating process may be carried out during normal production operations.

FIELD OF THE INVENTION

[0001] The invention relates to a new and improved apparatus and methodfor cleaning and lubricating conveyors using a microprocessor controlledcontrol system. The control system senses the activity of the conveyorand the presence of items on the conveyor, and in return lubricates andwashes the conveyor as needed. This automated system also reduces theamount of cleaning labor needed, as well as reduces the amount of wastedcleaning and lubricating supplies.

BACKGROUND OF THE INVENTION

[0002] Conveyors commonly used in the food and packaging industries (inparticular soft drink manufacturing facilities, breweries, fruit juicemanufacturing facilities, dairies, etc.) generally require periodiccleaning in order to maintain the conveyor in a sanitary condition. Thiscleanliness requirement in turn requires the application of variouscleaning ingredients such as detergents, sanitizers, bactericides,slimicides, etc. A simple, yet very time and labor intensive practice isto apply these cleaning ingredients to the conveyor system manually,either by high pressure hot water, steam, or other methods.Additionally, there is a tendency in manual cleaning to over-apply andwaste the cleaning products. This manual practice is both expensive,cumbersome and dangerous and may not provide an adequately cleanconveyor belt. The art recognizes a need for improved methods andapparatus. U.S. Pat. No. 5,372,243 provides an alternative to the abovedescribed cleaning method. King teaches a pneumatically controlledcleaning and rinsing system for conveyors. The valves for providingcleaning and rinsing ingredients are pneumatically actuated, as are thetimers and sequencer valves. Pneumatically controlled and actuatedequipment is stressed because of the desire to eliminate corrosion ofelectrical equipment and components in wet environments.

[0003] Others have provided alternate conveyor cleaning and/orlubricating systems to replace systems that include electricalequipment. U.S. Pat. No. 5,129,481 describes an apparatus and method forlubricating conveyors and belts used in the food industry comprising adevice including valves which are alternately opened and closed by anactuating device driven from the conveyor movement. The valves supply alubricant which is fed to output nozzles for spraying onto the conveyorsfor lubricating purposes, and the valves will only feed lubricant whenthe conveyor is moving. Alternately, U.S. Pat. No. 5,289,899 teaches anair-driven delay valve or relay, which is driven from the conveyorsystem, and which connects to a counter which controls the valve thatpasses lubricant in a pulsating or intermittent fashion.

[0004] However, pneumatically controlled systems, such as thosedescribed above, can be inaccurate, for example, in their timemeasurement and fluid dispensing, leading to ineffective cleaning and/orlubricating of the conveyor and wasted supplies. A substantial needexists for a cleaning and lubricating system for conveyors that issimple, accurate, versatile, reliable, and is easy to maintain.

SUMMARY OF THE INVENTION

[0005] The present invention relates to a new and improved apparatus andmethod for cleaning and lubricating conveyor systems using amicroprocessor controlled control system. The control system sensesmovement of the conveyor belt and the presence of any items, such ascans, bottles, or food products, on the conveyor belt, and in returneither cleans or lubricates the conveyor as needed. This automatedsystem reduces the amount of labor needed to perform these criticaltasks, as well as reduces the amount of wasted cleaning and lubricatingsupplies.

[0006] In particular, the present invention relates to a conveyor systemthat includes the combination of a conveyor system, a washing system,and a lubrication system. The conveyor system is for transporting anobject, with the conveyor system including a conveyor belt having afront side and a back side, and a drive mechanism for providing movementto the belt. The washing system is for rinsing and washing the conveyorbelt and includes a water source, a detergent source, a mixing chamberto mix the water and the detergent to form a cleaning solution, and anapplicator for application of the cleaning solution onto the belt. Insome embodiments, the applicator is a spray nozzle. The application ofthe cleaning solution onto the belt is controlled by a control system,which comprises a microprocessor adapted to provide a signal to open theapplicator to provide rinse or cleaning solution onto the belt. Thelubrication system is for lubricating the conveyor belt to improve belttracking and to extend the useable life of the belt. The lubricationsystem includes a lubricant source and an applicator for application ofthe lubricant onto the belt. In some embodiments, the applicator is aspray nozzle. The application of the lubricant onto the belt iscontrolled by a lubricant control system that includes a first sensingsystem to sense movement of the belt, a second sensing system to sensepresence of items on the belt, and a control system comprising amicroprocessor that receives signals from the sensing systems and sendssignals to open the applicator to provide lubricant onto the belt on apredetermined, timed basis.

[0007] The amount of lubricant applied to the belt is dependent on thesignals from the first and second sensing systems. In particular, if thefirst sensing system confirms movement of the belt and the secondsensing system confirms an object, the microprocessor provides a signalto provide lubricant so that a first amount of lubricant is fed from thelubricant source and is applied onto the conveyor. If the first sensingsystem confirms movement of the belt but the second sensing system doesnot confirm the presence of an object, the microprocessor provides asignal to provide lubricant so that a second amount of lubricant is fedfrom the lubricant source and is applied to the conveyor, the secondamount of lubricant being less than the first amount. If the firstsensing system does not confirm movement, whether or not items arepresent on the belt, the microprocessor does not provide a signal toapply lubricant.

[0008] In a further aspect of the invention, the washing systemcomprises a microprocessor to provide a signal to apply a rinse orcleaning solution to the conveyor belt for a predetermined timeinterval. Typically, this washing process occurs after any productionrun on the conveyor system is complete. The washing process generallyincludes a first rinse step, a cleaning step, and a second rinse step.

[0009] The invention will be further described in relation to theincluded drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010]FIG. 1 is a schematic perspective view showing an apparatus ofthis invention, including a conveyor system;

[0011]FIG. 2 is a simplified schematic diagram in top view of a conveyorsystem having multiple zones; and

[0012]FIG. 3 is a block diagram illustrating the logic used by theapparatus of this invention to provide the method for the lubricationand cleaning of the conveyor system.

DETAILED DESCRIPTION

[0013] The invention relates to a new and improved apparatus and methodfor cleaning and lubricating conveyors using a microprocessor controlledcontrol system. The control system senses the activity of the conveyorand the presence of items on the conveyor, and in return either cleansor lubricates the conveyor as needed. If the control system only sensesmovement of the conveyor but no item on the conveyor, only a smallamount of lubricant is applied to the conveyor sufficient to keep theconveyor belt properly lubricated.

[0014] Referring now to the Figures, wherein like elements arerepresented by like numerals throughout the various views, FIG. 1 showsa general arrangement of a conveyor maintenance system 100 that has alubrication system 200 and a washing system 300. The apparatus 100 isused for lubricating and washing a conveyor system 110, although notnecessarily simultaneously.

[0015] Conveyor system 110 includes a conveyor belt 120 having a frontside 122 and a back side 124, and a structure 115 to support belt 120.Front side 122 of belt 120 is the side on which items, such as bottlesor cans 50, are carried. Back side 124 is the inner side when belt 120is formed as a loop (as shown in FIG. 1), and back side 124 typicallycontacts a drive mechanism (not shown). Conveyor systems, such as thosedesignated as conveyor system 110, are well known.

[0016] Washing system 300 has a water source 302, a detergent source310, and a device in which the water and the detergent are mixed. InFIG. 1, such a mixing device is shown as mixing chamber 320. Watersource 302 is typically a potable water source and is generally suppliedat about 5 to 20 gallons per minute at a pressure of about 60 to 125psi, although other volumetric rates and pressures could be used.Detergent source 310 can be a drum 312, such as a 55 gallon drum, or alarger storage tank. The detergent may be any solution, mixture,component or the like used for cleaning, disinfecting, degreasing, etc.A low level alarm 316 may be used within detergent source 310 to warn oflow detergent supply. A controller 305 is used to control valves 304,314 which allow feed from water source 302 and detergent source 310,respectively, to flow to mixing chamber 320. Once the water anddetergent are mixed in a mixing device, for example, mixing chamber 320,the cleaning mixture or solution is applied to the conveyor belt. InFIG. 1, the solution is supplied via delivery pipe 330 to a detergentapplicator, shown as spray nozzle 350 (shown in phantom in FIG. 1).Spray nozzle 350 applies cleaning solution to back side 124 of conveyorbelt 120. Optionally, the cleaning solution could be applied to frontside 122 of conveyor belt 120 or other areas of conveyor system 110,such as structure 115.

[0017] In some steps during the washing procedure, it may be desired toprovide a water-only rinse of the conveyor system 110; that is, nodetergent is used. The process of washing is considered to compriserinsing. Rinsing is performed in the same manner as washing, except thattypically no detergent is added to provide the solution. There may,however, be additives provide to the water source to produce a rinsesolution. Often, a three-step process is used: a first rinse step, awashing or cleaning step, and a second rinse step.

[0018] The washing process, which includes the steps of applying rinseand/or cleaning solution, may be applied to conveyor belt 120 atpredetermined intervals, for example, a one to three minute rinse afterevery hour of operation. Rinse and/or cleaning solution may also, oralternately, be applied at the end of the production run that usesconveyor system 110, for example, at the end of the work day or shift.The conveyor belt 120 may continue to run (i.e., move) during thecleaning operation or may be stopped.

[0019] Generally, no sensors are needed in washing system 300 if it isdesired to rinse and/or washing conveyor belt 120 after its use. Thewashing may be activated by, for example, a manual switch after theproduction run has been completed.

[0020] Lubrication system 200 has a lubricant source 210 and a lubricantapplicator, such as spray nozzle 250, to apply lubricant to front side122 of conveyor belt 120. Optionally, the lubricant could be applied toback side 124 of conveyor belt 120. In accordance with the presentinvention, the amount of lubricant applied to belt 120 is dependent onboth the movement of conveyor belt 120 and the presence of items, suchas cans 50, on belt 120. If belt 120 is in motion and items are presenton the belt, a first amount of lubricant is applied to front side 122 ofbelt 120. If belt 120 is in motion and no items are present, a secondamount of lubricant is applied, with the second amount of lubricantbeing less that the first amount. If no movement of belt 120 is sensed,whether or not any items are present on belt 120, no lubricant isapplied. This series of inquiries and resulting actions is illustratedin FIG. 3, which is a block diagram of the logic used to determine theapplication of the lubricant.

[0021] Movement of belt 120 is sensed by a sensor 220, which in FIG. 1is positioned to monitor back side 124 of belt 120. Presence of items,such as cans 50, is sensed by sensor 225. FIG. 1 shows two sensors 225,225′ on opposites sides of belt 120 and mounted on structure 115.Although only one sensor 225 for monitoring the belt and two sensors225, 225′ for monitoring presence of items are shown, any number ofsensors can be used. Sensors 220, 225, 225′ may be any sensors capableof sensing movement and/or presence of items; usable sensors includewell known devices such as motion or vibration detectors, or laser, IRor other sensors. In another embodiment, the sensor may be directlywired or otherwise connected to the conveyor system's motor.

[0022] Sensors 220, 225, 225′ are connected to a control system 205which includes a microprocessor (not shown) therein. Signals fromsensors 220, 225, 225′ are processed by the microprocessor, which thensends a signal to valve 204 which controls supply of lubricant fromsource 210 to nozzle 250.

[0023] The microprocessor usable in the control system 205 of thepresent invention may be a programmable general purpose microprocessor,also known as a “PLC” or a programmable logic controller. ‘Ladder logic’is typically the format used when programming this microprocessor. Themicroprocessor is incorporated into the control system 205 and may beattached to equipment such as a monitor, touch screen, keyboard, or amouse. The microprocessor is then also connected to the sensors andvalves.

[0024] If sensor 220 provides a negative signal to control system 205indicating that belt 120 is not moving, control system 205 provides asignal to close valve 204 so that no lubricant is applied to belt 120.If sensor 220 provides a positive signal indicating that belt 120 is inmotion, and sensor 225 provides a positive signal indicating that itemssuch as cans 50 are present on belt 120, control system 205 provides asignal to open valve 204 so that a first amount of lubricant flows tonozzle 250 and is applied to belt 120. If sensor 220 provides a positivesignal indicating that belt 120 is moving, but sensor 225 provides anegative signal indicating that no items are present on belt 120,control system 205 provides a signal to open valve 204 partially so thata second amount of lubricant flows to nozzle 250 and is applied to belt120. The second amount of lubricant allowed through valve 204 andapplied by nozzle 250 is less that the first amount, because nolubrication is need between items and the belt if no items are present.The lubrication desired, when no items are present, is a minimal amount,simply to reduce friction and maintain flexibility of the belt.

[0025] Lubricant source 210 can be any container such as a drum, a largestorage tank, or can be supplied by a delivery pipe from a remotelocation. Valve 204 is preferably a pneumatic (air actuated) valve andis controlled by signals from control system 205. An air injection tee214 may be included in lubricant system 200 to provide a stream of airto be mixed with the lubricant before it is applied to belt 120.

[0026] Referring now to FIG. 2, a conveyor system 500 is typicallydivided into multiple zones, generally at least two zones, often morethan two zones. FIG. 2 shows conveyor system 500 with four zones. A“zone” is a region or length of conveyor and each zone typically has itsown conveyor belt, support framework, conveyor track, and drivemechanism for the conveyor belt. Often, a zone may have multipleconveyor belts that may or may not have their own drive mechanism.

[0027]FIG. 2 is a top simplified schematic diagram of conveyor system500 divided into four zones. Conveyor system 500 includes a fillerstation 520 where a container, such as a can or bottle, is filled.Conveyor belt 510 moves the container from one station, such as fillerstation 520, to the next station. From filler 520, the containerprogresses along conveyor belt 510 to seamer station 530 where thecontainer is sealed, e.g., capped. From seamer 530, the containerprogresses through a warmer station 540. After warmer 540, the containerprogresses to accumulation area 550, where multiple containers arestored until they are ready to be sent to caser station 560. At caser560, the containers are packaged for delivery and distribution, forexample, cans may be packaged in plastic 6-pack rings, or in paperboardboxes for 12 and 24 packs.

[0028] Conveyor system 500 is divided into four zones I, II, III, andIV, which extend from seamer 530 to caser 560. Zone I extends from afterseamer 530 to warmer 540, but could optionally start at filler 520. ZoneII extends from after warmer 540 to accumulation area 550. Afteraccumulation area 550, conveyor system 500 is divided into two zones,III and IV, which extend to caser station 560. In accordance with thepresent invention, each zone may include a system for controlling thelubricant and a system for controlling the rinse and cleaning solutions,the systems may, however, be shared with one or multiple additionalzones. In a preferred embodiment, a single control system is capable ofcontrolling all lubricant systems, without the need for an individualcontrol system for each lubrication system.

[0029] It should be noted that although FIG. 2 is schematically drawnshowing a single conveyor belt 510 extending the length of conveyorsystem 500, conveyor belt 510 actually may include multiple belts.Typically, each bend or turn in the system requires a new belt. Forexample, conveyor belt 510 a extends from filler station 520 to seamerstation 530. From seamer 530, two belts 510 b, 510 c extend to warmer540. Both belts 510 b, 510 c are within zone I. From warmer 540, belts510 d, 510 e, 510 f and 510 g in zone II extend to accumulation area550. Belt 510 h in zone III and belt 510I in zone IV extend to caserstation 560. Each belt 510 a, 510 b, etc., may have its own drivemechanism (not shown), or multiple belts may share a drive mechanism.

[0030] A single control system with a microprocessor can be used tocontrol all lubricant systems that apply lubricant to belts 510 a, 510b, etc. Similarly, a single control system with a microprocessor can beused to control all washing systems.

[0031] The above-captioned drawings, explanation and specificationdescribe the elements of the conveyor system lubrication and washingsystem and its method of use. While a variety of embodiments can be madewithout departing from the spirit and scope of the invention, theinvention resides in the claims hereinafter appended.

We claim:
 1. A combination lubricating and cleaning system for anoperating conveyor system, the system comprising: (a) a conveyor fortransporting an object, the conveyor comprising a belt having a frontside and a back side, driven by a drive mechanism; (b) a washing systemcomprising a water source, a detergent source, a mixer to mix the waterand the detergent to form a cleaning solution, a detergent applicator toapply the cleaning solution onto the belt, and a control system, thecontrol system comprising a microprocessor adapted to apply the cleaningsolution onto the belt; and (c) a lubrication system comprising alubricant source, a lubricant applicator to apply lubricant onto thebelt, and a lubricant control system, the lubricant control systemcomprising: (i) a first sensing system to sense movement of the belt;(ii) a second sensing system to sense presence of items on the belt; and(iii) a control system comprising a microprocessor adapted to open thenozzle to spray lubricant onto the belt, wherein if the first sensingsystem confirms movement of the belt and the second sensing systemconfirms an object, the microprocessor provides a signal to open thelubricant applicator so that a first amount of lubricant is fed from thelubricant source and is applied onto the conveyor; and if the firstsensing system confirms movement of the belt but the second sensingsystem does not confirm an object, the microprocessor provides a signalto open the lubricant applicator so that a second amount of lubricant isfed from the lubricant source and is applied to the conveyor, the secondamount of lubricant being less than the first amount; and if the firstsensing system does not confirm movement, the microprocessor does notprovide a signal to open the lubricant applicator.
 2. The combinationsystem according to claim 1 , wherein the lubricant applicator comprisesa spray nozzle.
 3. The combination system according to claim 1 , whereinthe detergent applicator comprises a spray nozzle and the mixercomprises a mixing chamber.
 4. The combination system according to claim1 , wherein the system comprises two zones, wherein each zone comprisesa conveyor; a solenoid, a valve and a controller configured and arrangedto control the lubricant; and a solenoid, a valve and a controllerconfigured and arranged to control the cleaning solution.
 5. Thecombination system according to claim 1 , wherein the system comprisestwo or more zones, wherein each zone comprises a conveyor; a solenoid, avalve and a controller configured and arranged to control the lubricant;and a solenoid, a valve and a controller configured and arranged tocontrol the cleaning solution.
 6. The combination system according toclaim 5 , wherein the two or more zones are arranged between a fillerstation and a caser station.
 7. The combination system of claim 1wherein the microprocessor for the cleaning system is the same as themicroprocessor for the lubricating system.
 8. A conveyor lubricatingsystem for application of lubricant onto a conveyor system, the conveyorsystem used for moving items on a belt and having a track, thelubrication system comprising: a lubricant source, a lubricantapplicator for application of the lubricant onto the tracks, and acontrol system, the control system comprising: (i) a first sensingsystem to sense movement of the belt; (ii) a second sensing system tosense presence of items on the belt; (iii) a microprocessor to open thenozzle to spray lubricant onto the belt; wherein if the first sensingsystem confirms movement of the belt and the second sensing systemconfirms an object, the microprocessor provides a signal to open thelubricant applicator so that a first amount of lubricant is fed from thelubricant source and is applied onto the tracks; and if the firstsensing system confirms movement but the second sensing system does notconfirm an object, the microprocessor provides a signal to open thelubricant applicator so that a second amount of lubricant is fed fromthe lubricant source and is applied to the tracks, the second amount oflubricant being less than the first amount; and if the first sensingsystem does not confirm movement, the microprocessor does not provide asignal to open the lubricant applicator.
 9. The conveyor lubricantsystem according to claim 8 , wherein the lubricant applicator is aspray nozzle.
 10. A conveyor cleaning system for cleaning a conveyorsystem used for moving items on a belt, the cleaning system comprising:a liquid source for providing a liquid; an applicator for application ofthe liquid onto the belt; a microprocessor to provide a signal to openthe nozzle to spray the liquid.
 11. The cleaning system according toclaim 10 wherein the liquid source is a water source and the liquid iswater.
 12. The cleaning system according to claim 10 , wherein theapplicator is a spray nozzle.
 13. The cleaning system according to claim11 further comprising: a detergent source for providing a detergent; anda mixing chamber for mixing the water and the detergent to form asolution.
 14. The cleaning system according to claim 13 , wherein thesystem comprises two or more zones, wherein each zone comprises asolenoid, a valve and a controller configured and arranged to controlthe mixing of the water and the detergent to form the solution.
 15. Thecleaning system according to claim 11 , wherein the microprocessorprovides a signal to apply the liquid for a period every hour theconveyor system is in use, the period being from one to three minutes.16. The cleaning system according to claim 11 , wherein themicroprocessor provides a signal to apply the liquid after the conveyorsystem has been used.